cie al S nce ri s te & a E Ojo, et al., J Material Sci Eng 2015, 4:4 M n f g DOI: 10.4172/2169-0022.1000174 o i n l e a e n r r i n u g o Journal of Material Sciences & Engineering J ISSN: 2169-0022 Research Article Article OpenOpen Access Access Experimental Analysis for Lubricant and Punch Selection in Shear Extrusion of Aa-6063 Ojo SO1*, Erinosho M2 and Ajiboye JS3 1Department of Structural, Geotechnical and Building Engineering, Politecnico di Torino, C.so Ducadegli Abruzzi 24, 10129 Torino, Italy 2Department of Mechanical Engineering Science, University of Johannesburg, Auckland Kingsway Campus, Johannesburg, 2006, South Africa 3Department of Mechanical Engineering, University of Lagos, Nigeria Abstract Shear extrusion is a forming process which is based on combined backward cup-forward rod extrusion. This extrusion process is attractive due its potential to achieve severe plastic deformation thus enabling texture and microstructural control of materials. Furthermore, the economic potential of shear extrusion for mass production and production of complex shapes provides for numerous applications in automotive, transportation, aero-space and other industries. However, a trending challenge in the use of this method for complex shapes is the design and selection of tools to achieve a high quality product. This paper focuses on deep study of shear extrusion of AA-6063. The process was studied experimentally using variables which affect the forming load as well as the quality of the product. It is concluded from the load-displacement and stress plots that a punch with large diameter and small punch land is desirable for easy forming of the material during shear extrusion. Analysis of the effect of lubricants on deformation load and stress shows that palm oil lubricant remains the best lubricant of the four lubricants examined since its gives the minimum load obtained during shear extrusion. Keywords: Shear extrusion; Severe plastic deformation; Lubricant; extrusion provides for numerous applications of structural materials Punch in automotive, transportation, aero-space and other industries [9,10]. Introduction Hu performed a coupled thermomechanical finite element simulation on the defect of extrusion and submitted that the use of Shear extrusion theory was derived from combined backward hyperbolic curve die leads to improved homogeneity of metal flow, cup- forward rod extrusion (BC-FRE) theoryand it involves shearing increased uniformity and less chance of formation of dead zone deformation during the metal forming process, a characteristic which whereas parabolic curve may cause continuous cracks on the surface of makes the process to be labour saving. Chang and Mousavi showed the extruded rods [11]. The use of shear die in the extrusion of complex that the extrusion force in shear-extrusion method of severe plastic shapes leads to a complicated problem of metal flow imbalance that deformation for fabrication of metal shapes with ultra-fine structures often results in shape defects and to obtain a straight and true product is far lower than that of simple forward rod extrusion (FRE) or in size, the design of the location of the die orifice and the specification backward cup extrusion (BCE) [1,2]. By using an aluminium billet of various sizes, Chang concluded that decrease of the extrusion force of the die land length is of paramount importance [11-13]. Other was significant especially when the inner diameter of the cup is less die process parameters which may affect the quality of the extrudate than the outer diameter of the rod such that the directly compressed are the shape ratio of the billet, extrusion ratio and the capacity of zone is reduced to zero, and the deformation zone becomes the the extrusion press [14]. The flow and movement of a punch during deformation band. Although differential speed rolling (DSR) and equal deformation by extrusion process is dependent on the magnitude of the speed rolling (ESR) are some of the attractive techniques employed maximum pressure and the geometry of the die coupled with the billet for enhanced plasticity and textural control in metal forming process configurations [15]. Murai in his work concluded that the extrusion [3-5]. Hu shows that compound extrusion technology, a combination load increases with the shape ratio of the billet and the forward and of extrusion and shear process is capable of effective grain refinement backward extruded lengths can be predicted from the diameter, height of metals due to accumulation of high strain and low temperature and flow stress of a billet [16]. To determine the extrusion pressure, rise [6]. Furthermore, Utsunomiya work on continuous deformation Altanperformed a slab method analysis in which he takes account of process reveals that shear extrusion can also be used as a textural parameters namely, frictional shear stress at the dead-metal/flowing and microstructural control method for metal strips by introducing metal interface and frictional shear stress at the billet-container shear textures in addition to its capacity of being highly productive interface [17]. He proposed the average extrusion pressure as [7]. This observation is corroborated by Thomas in where he further highlighted other important advantages of the shear extrusion process [8]. First, this is a one-step technique of severe plastic deformation that *Corresponding author: Ojo SO, Department of Structural, Geotechnical and does not require strain accumulation during multi-pass processing. Building Engineering, Politecnico di Torino, C.so Ducadegli Abruzzi 24, 10129 Second, long complicated shapes including hollow ones can be formed Torino, Italy, Tel:39 011 090 6111; E-mail: [email protected] simultaneously with the structure refinement to the sub-micron scale. Received May 13, 2015; Accepted May 27, 2015; Published June 12, 2015 Third, severe deformation is performed under high and controllable Citation: Ojo SO, Erinosho M, Ajiboye JS (2015) Experimental Analysis for hydrostatic pressures. Therefore, the structure refinement of usually Lubricant and Punch Selection in Shear Extrusion of Aa-6063. J Material Sci Eng brittle alloys is possible with significant improvement in their strength 4: 174. doi:10.4172/2169-0022.1000174 and toughness. Fourth, processing characteristics of the shear-extrusion Copyright: © 2015 Ojo SO, et al. This is an open-access article distributed under method provide high productivity and low product cost which are the terms of the Creative Commons Attribution License, which permits unrestricted comparative to the ordinary extrusion methods. Therefore, shear use, distribution, and reproduction in any medium, provided the original author and source are credited. J Material Sci Eng ISSN: 2169-0022 JME, an open access journal Volume 4 • Issue 4 • 1000174 Citation: Ojo SO, Erinosho M, Ajiboye JS (2015) Experimental Analysis for Lubricant and Punch Selection in Shear Extrusion of Aa-6063. J Material Sci Eng 4: 174. doi:10.4172/2169-0022.1000174 Page 2 of 5 cotα D of properties, relevant to both use and production as a result of its C (1) Pave,z= 0 =2σ 1 + ln ln strength (150-350 MPa), all with good toughness and formability. With 3 DE the lower limit of Mg and Si for example, 6060 and 6063 extrude at high speeds with good surface finish, anodizing capability and maximum D where C is the equivalent diameter of the billet (container bore complexity of section shape can be combined with high section D diameter) filled in the container after upsetting, where E , the thickness. Their properties made them find wide use in architectural equivalent diameter of extruded rod, α is the semi dead-metal zone applications where shape and finish are more important than strength angle and σ is the flow stress of the material (Figure 1). [18]. The 6000 (AA-Mg-Si) series alloys have an attractive combination In this paper, experimental analysis for punch and lubricant selection is conducted for shear extrusion process of AA-6063 and it is showed that a careful control of the process parameters can be utilized to obtain better product quality from shear extrusion. Die Design Considerations in the choice of equipment and tooling needed for the experiment involves design of extrusion die, punch design, selection of press, and design of fixture and other accessories to be used in the execution of the task [19,20]. The die assembly was designed for easy replacement of punches of varying sizes. The die stack consists of the die body, die shoe and punch plate. The die was constructed as a flat faced die in order to allow Figure 1: A billet geometry inside a container. metal upon entering the die to shear internally to form its own die angle (Figure 2a-d). A parallel land on the exit side of the die helps strengthen the die and allow for reworking of flat face on the entrance side of the die without increasing the exit diameter. The diameter of the die bore ( DC ) is 25 mm while the die exit area is ( DE ) is 20 mm. The areas of the die bore AC and the die exit are calculated by the formula π D 2 A =C = 490.9 mm2, C 4 b a 2 π DE 2 AE = = 314.2 mm 4 Punch design The maximum allowable punch length, Lm is calculated using the formula [21] D ED 1/2 Lm = π () (2) 8 fts Where D is the punch diameter in mm, fs is the shear strength of high carbon steel, t is the material thickness and E is the modulus of elasticity of high carbon steel. The value of these parameters used for c the punch design is given in Table 1. D/t= 1.1 or higher Based on the formula in eq. (2), the calculated maximum punch length for the punch with the smallest diameter is 80 mm. Therefore, the selected punch length is 60.